Corrosion-responsive coating formulations for protection of metal surfaces

a technology for corrosion-responsive coatings and metal surfaces, applied in the direction of non-metal conductors, other chemical processes, conductors, etc., can solve the problems of affecting the use of hexavalent chromium in the aerospace sector, affecting the cost of direct loss of metallic corrosion, and lacking current coating strategies, etc., to achieve the effect of low spontaneous release ra

Inactive Publication Date: 2009-10-13
LUMIMOVE
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0030]Among the several advantages found to be achieved by the present invention, therefore, may be noted the provision of corrosion-inhibiting methods and compositions that provided effective corrosion protection for metal surfaces; and also the provision of such methods and compositions that supply corrosion-inhibiting agents in response to actual corrosion on a metal surface; and also the provision of such methods and compositions that provide corrosion protection for pinholes and scratches that might occur on the metal surfaces; and also the provision of such methods and compositions that retain their effectiveness through normal weather exposure.

Problems solved by technology

In the United States approximately $300 billion per year in direct costs is lost due to metallic corrosion.
What is lacking with current coating strategies, however, is an environmentally friendly coating system that prevents corrosion and pitting even in the presence of pinholes or scratches.
Problems with a passivation coating, such as chromium VI (the form of chromium commonly used in aerospace coatings), include the fact that chromium is a carcinogen and federal, state and local agencies have issued regulations that limit or prohibit the use of chromated materials.
OSHA's proposed PEL would severely impact the use of hexavalent chromium throughout the aerospace sector.
However, such coatings often lack pinhole protection.
Any pitting or scarring that penetrates the underlying structures can lead to catastrophic corrosion damage.
These coatings wear more readily, and the layer thickness and its associated weight can negatively impact structural design.
One drawback of many polymeric systems, however, is the use of solvents, or the formation of water or gas during curing.
Despite the availability of radiation-cured polymeric systems, they have not been widely used to form corrosion-resisting coatings, and certain problems remain to be resolved.

Method used

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  • Corrosion-responsive coating formulations for protection of metal surfaces
  • Corrosion-responsive coating formulations for protection of metal surfaces
  • Corrosion-responsive coating formulations for protection of metal surfaces

Examples

Experimental program
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Effect test

example 1

[0102]This illustrates the production of poly(2,5-dimercapto-1,3,4-thiadiazole).

[0103]2,5-dimercapto-1,3,4-thiadiazole (25 grams, DMcT, available from Sigma-Aldrich, Milwaukee, Wis.) was added to 50 / 50 deionized water / methanol (1500 ml). Sodium hydroxide (6.66 grams) was then added to the mixture with stirring until the mixture became a clear transparent yellow. The mixture was heated to about 45° C. with stirring. In a separate flask, iodine (42.13 grams) was dissolved in methanol (400 ml) transferred to an addition funnel that is attached to the round-bottom flask holding the DMcT mixture. The iodine solution was added dropwise to the DMcT mixture in the flask with stirring over a period of about 30 minutes. A precipitate formed immediately and was initially white, but became reddish brown as the iodine solution was added. After stirring for 2 hours, the product was recovered by filtration, and the product was washed with acetonitrile, methanol and deionized water. The solid produ...

example 2

[0104]This illustrates the production of polyaniline doped with (2,5-dimercapto-1,3,4-thiadiazole).

Synthesis of DMcT-salt of polyaniline (Blender Method):

[0105]2,5-dimercapto-1,3,4-thiadiazole (93 grams) was ground in a mortar with a pestle to a fine powder. The powder was added to deionized water in a Waring blender and emulsified in the blender for 1 minute. Aniline (57 grams) was added to the mixture in the blender and emulsified for 1 minute. The mixture in the blender was transferred to a 3 liter round-bottom jacketed flask that was cooled to about 5° C. and blanketed with nitrogen. Ammonium peroxidisulfate (170 grams, APDS) was dissolved in deionized water and transferred to an addition funnel, which was attached to the round-bottom flask. The APDS solution was then added dropwise to the mixture in the flask over a period of about 15 minutes while maintaining the temperature of the mixture in the flask below about 5° C. The mixture was stirred for 3 hours at about 5° C. under ...

example 3

[0114]This illustrates the production of UV-curable coating formulations containing (2,5-dimercapto-1,3,4-thiadiazole), poly(2,5-dimercapto-1,3,4-thiadiazole), and polyaniline doped with (2,5-dimercapto-1,3,4-thiadiazole).

[0115]A measured amount of a UV-curable resin (160 g; available as FD3007CI UV, from Allied PhotoChemical, Kimball, Mich.) was charged to an Eiger Mini Mill (Model 100 VSE; Eiger Machinery, Inc., Grayslake, Ill.), and an amount (17.78 g dry weight) of a corrosion-responsive agent, selected from 2,5-dimercapto-1,3,4-thiadiazole (DMcT), poly(2,5-dimercapto-1,3,4-thiadiazole), and polyaniline doped with (2,5-dimercapto-1,3,4-thiadiazole) (Pani-DMcT) was added as a solid material to the liquid to give a mixture that was 10% by weight corrosion-responsive agent. The solids and the liquid were milled until the solids were of the desired particle size and were well-dispersed in the liquid.

[0116]A known weight (100 g) of the 10% w / w mixture was drawn from the mill, and 77....

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Abstract

Methods and compositions are described for protecting a metal surface against corrosion. The method involves applying to the metal surface a coating formulation that comprises a radiation curable resin and a corrosion-responsive agent that is capable of releasing a corrosion-inhibiting ion in response to exposure to ionic species characteristic of those present on a metal surface undergoing oxidative corrosion; and exposing the coating formulation to radiation whereby the radiation curable resin forms a corrosion-resisting coating having a low spontaneous release rate of the corrosion-responsive agent into the environment.

Description

CROSS REFERENCE TO RELATED PATENTS AND PATENT APPLICATIONS[0001]The present application is a divisional of U.S. Non-Provisional patent application Ser. No. 10 / 454,347, filed Jun. 4, 2003, which claims priority to U.S. Provisional Patent Application Ser. No. 60 / 386,058, filed Jun. 4, 2002, and to U.S. Provisional Application Ser. No. 60 / 466,298, filed Apr. 29, 2003, each of which is incorporated herein by reference in its entirety.BACKGROUND OF THE INVENTION[0002](1) Field of the Invention[0003]The present invention relates to coatings for metal surfaces that protect the surfaces from corrosion, and more particularly to radiation curable corrosion-responsive coatings for metals and components of such coatings.[0004](2) Description of the Related Art[0005]In the United States approximately $300 billion per year in direct costs is lost due to metallic corrosion. More than one third of costs are considered avoidable using existing know-how and technology. Coatings are the primary and mo...

Claims

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Application Information

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Patent Type & Authority Patents(United States)
IPC IPC(8): H01B1/00C01B3/02C08G73/00C08G75/00C23F11/00C08F2/44B05D3/06C08F2/46C09D4/02C09D5/00C09D5/08C09D7/12C09D165/00C09D179/02C09D201/00C23F15/00
CPCC08F2/46C23F11/00C09D165/00C09D179/02C09D5/082B05D3/067B05D2202/00
Inventor KINLEN, PATRICK J.
Owner LUMIMOVE
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